Multiple component web

ABSTRACT

Methods and apparatus for assembly of extensible composite webs and web sausages, and personal care articles manufactured from such webs. The invention comprises fabricating a resiliently extensible web by bringing together and securing to each other as discrete elements, intervening web substrate elements between resiliently stretchable elastic elements. Securement between elastic elements and web substrate elements is defined by alternating zones of securement and non-securement along a length of the web substrate. The invention comprises deactivating elastic elements in the non-securement zones thereby to retract elastic strands in the non-securement zones without retracting the corresponding web or webs in such non-securement zones, and correspondingly, to distinguish the securement zones as relatively more resiliently stretchable and the non-securement zones as relatively less resiliently stretchable. The invention further comprises applying, to the relatively non-stretchable non-securement zones, fastener material extending generally between adjacent ones of the relatively more resiliently stretchable securement zones.

RELATED APPLICATION

[0001] The present application is a divisional application based onco-pending U.S. patent application Ser. No. 09/834,870, filed Apr. 13,2001.

BACKGROUND

[0002] This invention relates to manufacture of, e.g. absorbent,personal care articles, especially to methods and apparatus for assemblyof multiple component extensible webs, and personal care articlesmanufactured from such webs. More specifically, this invention relatesto methods and apparatus for assembly of webs, preferably extensiblewebs, and personal care articles manufactured therefrom wherein themethods and apparatus of the invention diminish inefficient attributesof methods associated with conventional processes for manufacturingpersonal care articles. While embodiments of the present invention aredescribed herein in terms of personal care articles such as pull-onpants or adult incontinence briefs, the invention includes, and isequally applicable to, infant diapers, training pants, and like personalcare articles.

[0003] In conventional methods for fabricating personal care absorbentarticles, it is known to build workpieces on a uniform, continuous webor webs as the web or webs advance through a series of work stations ona manufacturing line, wherein each work station effects a modificationto a web or workpiece element, such as cuts or additions of absorbentarticle components to such web, webs, or workpiece element. Individualworkpieces are then severed from the uniform continuous web or webs toform individual absorbent personal care articles or article blanks. Insuch conventional methods for fabricating personal care articles,ancillary components, such as fastener tabs and fastening areas orlanding zones, are affixed to such articles or article blanks either atthe work stations of such manufacturing line or at a subsequent stage inthe manufacturing process after separation of such articles or articleblanks from the web or webs.

[0004] A need exists for improved methods for production of personalcare absorbent articles wherein the methods are effective to reducematerial waste and to improve time efficiency of the manufacturingprocess as well as to reduce financial waste inevitably associated withtime inefficiency of such manufacturing process. A need exists forimproved methods for production of personal care absorbent articleswherein the methods are effective to attenuate material waste and timeinefficiency associated with conventional manufacturing processes aswell as to reduce the financial burden associated with suchinefficiencies and waste.

[0005] Thus, it is an object of the invention to provide improvedmethods for production of personal care absorbent articles whichimplement a more “manufacture-friendly” extensible web as a basestructure from which to assemble personal care absorbent articles,enabling a manufacturer to assemble such articles while employingrelatively fewer work stations on the manufacturing line, compared toconventional methods, thus reducing production time.

[0006] It is another object of the invention to provide improvedmanufacturing methods which include fabricating a web of indefinitelength by adding alternating workpieces and intervening elements to theweb segment so as to develop a self-supporting web of indefinite length,wherein support of such self-supporting web along the indefinite lengthof such web is primarily defined by the alternating workpieces andintervening elements making up the web.

[0007] It is yet another object of the invention to provide improvedmanufacturing methods including defining, in the workpieces, mechanicalfasteners effective to engage the intervening elements.

[0008] It is a further object of the invention to provide improvedmanufacturing methods wherein the releasable attachment of theworkpieces to the intervening elements comprises the only attachmentbetween the workpieces and the intervening elements.

[0009] It is a still further object of the invention to provide improvedmanufacturing methods which reduce the relative quantity of raw materialwhich is wasted in the manufacturing of personal care-type articles.

SUMMARY

[0010] In a first family of embodiments, the invention comprehends amethod of fabricating a web suitable for use in making a personal careabsorbent article. The method comprises fabricating a resilientlyextensible web by bringing together and securing to each other websubstrate elements and resiliently stretchable elastic elements instretched condition. The securement between the elastic elements and theweb substrate elements is defined by alternating zones of securement andnon-securement of the elastic elements to at least one of the websubstrate elements along a length of the web substrate. The method alsoincludes deactivating elastic elements in the non-securement zonesthereby to attenuate resilient retraction of the web in suchnon-securement zones in response to activity of the elastics, andcorrespondingly, to distinguish the securement zones as relatively moreresiliently stretchable and the non-securement zones as relatively lessresiliently stretchable. The method further includes applying, to therelatively non-stretchable non-securement zones, patches of mechanicalfastener material extending generally between respective adjacent onesof the relatively more resiliently stretchable securement zones.

[0011] In preferred embodiments, the invention comprises fabricating aworkpiece suitable for use in a personal care article including defininga first end of such workpiece in the web by defining a free end of theweb through a respective patch of the hook fastener material, andseparating the workpiece from the web through a second respective patchof the hook fastener material such that hook fastener patch material isdefined at opposing end portions of the respective workpiece.

[0012] In such preferred embodiments, the invention can comprisefabricating an extensible web from respective ones of first and secondworkpieces, wherein such web is suitable for use as a substrate inmaking a personal care article. The method comprises arrangingworkpieces in generally end-to-end relationship with interveningelements, and releasably attaching the hook material on the workpiecesto hook receptive areas on the intervening elements, thus to releasablyattach the workpieces to the intervening elements in fabricating alength of the extensible web.

[0013] The releasable attachment of the workpieces to the interveningelements comprises the primary structural attachment, and preferably theonly attachment, between the workpieces and the intervening elements.

[0014] The method can comprise developing an alternating arrangement ofthe workpieces and the intervening elements such that each suchworkpiece is between two such intervening elements and each suchintervening element is between two such workpieces.

[0015] In some embodiments, the method comprises arranging workpieces ingenerally end-to-end relationship with intervening elements, respectiveones of the intervening elements having lengths and widths definingrespective surface areas, the hook receptive areas of such respectiveintervening elements generally corresponding to such surface areas. Suchmethod includes releasably attaching the hook material on the workpiecesto the intervening elements at the hook receptive areas, thus toreleasably attach the workpieces and the intervening elements to eachother in fabricating a length of the extensible web.

[0016] Methods of the invention typically include deactivating elasticelements in the non-securement zones preferably by cutting such elasticelements or by applying ultrasonic energy to such elastic elementsoptionally through an intervening layer.

[0017] In a second family of embodiments, the invention comprehends amethod comprising fabricating a base web comprising multiple workpieces,applying patches of mechanical fastener material to such base web, anddefining a first end of such workpiece by defining a free end of thebase web through a respective patch of the fastener material, andseparating the workpiece from the base web through a second respectivepatch of the fastener material such that a patch of fastener material isdefined at both opposing end portions of the respective workpiece.

[0018] In preferred embodiments, the method includes arrangingworkpieces in generally end-to-end relationship with interveningelements, and releasably attaching the fastener material on theworkpieces to fastener receptive areas on the intervening elements, thusto releasably attach the workpieces to the intervening elements infabricating a length of composite web.

[0019] In some embodiments, the fastener material comprises a mechanicalhook material.

[0020] In preferred embodiments, the intervening elements comprise amaterial which demonstrates fastener receptive properties, wherein thematerial of the intervening element is capable of forming engagementrelationships with respective fastener materials.

[0021] In some embodiments, the method includes affixing the fastenerreceptive area, as a separate web element, to the intervening element,wherein the fastener receptive area has distinct physical edges.

[0022] In other embodiments, the fastener receptive area is integralwith a major surface of the intervening element. The fastener receptivearea is, thus, void of distinct physical edges.

[0023] In preferred embodiments, the base web comprises a neck-bondedlaminate or a stretch-bonded laminate.

[0024] In a third family of embodiments, the invention comprehends amethod of fabricating a self-supporting web of material from respectiveworkpieces and intervening elements, wherein such self-supporting web issuitable for use as a substrate in making a personal care article. Themethod comprises bringing together an intervening element having firstand second ends, a first workpiece having third and fourth ends, and asecond workpiece having fifth and sixth ends, with first, second, andthird lengths of the respective first and second workpieces and theintervening element aligned with each other in a generally commonsurface, and with the second and third lengths of the first and secondworkpieces operating as extensions of the first length of theintervening element, on opposing ones of the first and second ends ofthe intervening element. The method also includes releasably attachingthe first workpiece and the intervening element to each other at therespective first and fourth ends, using releasable fasteners, andreleasably attaching the second workpiece and the intervening element toeach other at the respective second and fifth ends, using releasablefasteners, such that the first, second, and third lengths, incombination, define a self-supporting web segment having a fourthlength. The fourth length of the web segment so defined by thecombination of the first, second, and third lengths is greater than anyof the first, second, and third lengths, individually, of the respectivefirst and second workpieces and the intervening element. Additional suchalternating workpieces and intervening elements can be releasablyattached to one or both of the third and sixth ends of the respectivefirst and second workpieces using additional releasable fasteners, tothereby further extend the length of the self-supporting web, whereinthe releasable fasteners employed in so assembling the self-supportingweb can be released so as to release respective ones of the workpiecesand intervening elements of the self-supporting web from each other.

[0025] In some embodiments, the second and third lengths of the firstand second workpieces are defined at rest, wherein the first and secondworkpieces are resiliently extensible by at least 100 percent of therespective second and third lengths, the method including attaching thefirst and second workpieces to the intervening element while therespective first and second workpieces are stretched substantially tostop.

[0026] In other embodiments, the method includes attaching the first andsecond workpieces to the intervening element while the respective firstand second workpieces are being subjected to a stretching tensionstretching the lengths of the respective first and second workpieces atleast 50 percent from the respective second and third lengths.

[0027] In yet other embodiments, the first and second workpiecesdemonstrate effectively no elasticity. In such embodiments, the methodinvolves substantially no stretching of the first and second workpieces,and simply includes attaching the first and second workpieces to theintervening element.

[0028] In preferred embodiments, the first and second workpieces areattached to the intervening element by fasteners having attachmentcapability over a substantial portion of an area defining theintervening element.

[0029] The first and second workpieces are preferably attached to theintervening element by first and second attachments defining mechanicalfasteners on one of the respective workpieces and/or the interveningelement interacting with mechanical loops on the other of the respectiveworkpiece and/or the intervening element.

[0030] In some embodiments, the method includes fabricating a web ofindefinite length by adding alternating workpieces and interveningelements to the web segment so as to develop a self-supporting web ofindefinite length wherein support of such self-supporting web along theindefinite length of such web is defined by the alternating workpiecesand intervening elements making up the web.

[0031] Some embodiments of the method include defining, in theworkpieces, mechanical fasteners effective to engage the interveningelements.

[0032] In a fourth family of embodiments, the invention comprehends aself-supporting web of sheet material suitable for use in making apersonal care article, the self-supporting web comprising a sequence ofat least first and second workpieces and intervening elements, includingopposing ends on the respective workpieces and intervening elements. Therespective workpieces and intervening elements have unstressed lengthsbetween the respective ends thereof, the unstressed lengths of therespective workpieces and intervening elements being aligned with eachother in a generally common surface, and operating as extensions of eachother, such that the unstressed lengths, in combination, define a lengthof the web. The workpieces and intervening elements, in combination,generally define self-supporting longitudinal strength of the web. Theworkpieces and intervening elements are releasably attached to eachother, using releasable fasteners, wherein the releasable fastenersemployed in so assembling the web can be released so as to releaserespective ones of the workpieces and intervening elements from theself-supporting web.

[0033] In some embodiments, ones of the workpieces can be resilientlyextended at least 100 percent from the unstressed lengths of therespective workpieces.

[0034] Preferred embodiments include employing hook and loop fasteningstructure in effecting the releasable fastening of the workpieces andintervening elements.

[0035] In a fifth family of embodiments, the invention comprehends amethod of fabricating personal care absorbent articles. The methodincludes advancing along a processing line a first web having a firstlength. The first web is suitable for use in making a personal carearticle, and comprises at least workpieces and intervening elementsreleasably attached to each other using releasable fasteners to therebydefine such first web and self-supporting longitudinal strength of suchweb, whereby such workpieces and intervening elements generally definethe structure and the structural integrity of the first web. The methodalso includes concurrently advancing a second web having a second lengthalong the processing line and generally parallel to the first web, anddefining a space between the first and second webs, the second web beingsuitable for use in making such personal care article. The methodfurther includes applying and attaching absorbent crotch portionelements to the first and second webs at spaced intervals along thelengths of the respective webs, and bridging the space between the firstand second webs, thereby to form a composite web comprising the firstand second webs and the respective crotch portions, wherein a givenrespective crotch portion element has a front segment attached to thefirst web and a rear segment attached to the second web. Additionally,the method includes bringing the first and second webs of the compositeweb into facing relationship with each other, including bringing therespective front and rear segments of the respective crotch portionelements generally into facing relationship with each other. The methodalso includes forming side seam bonds joining the first and second websto each other at spaced locations along the length of the composite web,thereby to form a composite web sausage having an indefinite length. Themethod further includes separating discrete lengths of the composite websausage from the indefinite-length composite web sausage at or proximaterespective ones of the side seam bonds, thereby to define respectivepersonal care articles.

[0036] In a sixth family of embodiments, the invention comprehends apersonal care article comprising a front portion, a rear portion, and acrotch portion extending between the front portion and the rear portion.The front and rear portions each comprise opposing first and second sidesections and a central section between the respective side sections, therear portion and the front portion being attached to each other atrespective side sections of the front and rear portions by side seams.The front portion comprises first and second workpieces corresponding tothe side sections of the front portion, and an intervening elementcorresponding to the front central section, the first and secondworkpieces being releasably attached to the intervening element byreleasable fasteners. The releasable fasteners, prior to use by a user,comprise the only attachment attaching the first and second workpiecesto the front central section.

[0037] In preferred embodiments, the releasable fasteners comprisemechanical fasteners, received in hook receptive material defined at theintervening element.

[0038] In some embodiments, the first and second workpieces are attachedto the intervening element by fasteners having attachment capabilityover a substantial portion of an area defining the intervening element.

[0039] In some embodiments, the first and second workpieces are attachedto the intervening element by first and second attachments definingmechanical fasteners on one of the respective workpieces and/or theintervening element interacting with mechanical loops on the other ofthe respective workpieces and/or the intervening element.

BRIEF DESCRIPTION OF THE DRAWINGS

[0040]FIG. 1A shows a representative top view of a method ofmanufacturing resiliently extensible web components of the invention.

[0041]FIG. 1B shows a top view of a resiliently extensible web componentof the invention.

[0042]FIG. 1C shows a representative side elevation view of amanufacturing line of the invention processing resiliently extensibleweb components of the invention.

[0043]FIG. 2A shows a representative top view of a process ofmanufacturing intervening elements of the invention.

[0044]FIG. 2B shows a top view of an intervening element of theinvention.

[0045]FIG. 3 shows a representative top view of an extensible web of theinvention.

[0046]FIG. 4 shows a pictorial view of a representative personal carearticle of the invention.

[0047]FIG. 5 shows a top view of a representative assembly method forfabricating personal care articles of the invention.

[0048] The invention is not limited in its application to the details ofconstruction or the arrangement of the components set forth in thefollowing description or illustrated in the drawings. The invention iscapable of other embodiments or of being practiced or carried out inother various ways. Also, it is to be understood that the terminologyand phraseology employed herein is for purpose of description andillustration and should not be regarded as limiting. Like referencenumerals are used to indicate like components.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0049] Referring to FIG. 1A, the invention comprehends apparatus andmethods for fabricating a web suitable for use in making personal careabsorbent articles. Respective segments of the exemplary illustratedmanufacturing process of the invention are indicated by letters “A-F”.Process segments “A, C, D, E” of FIG. 1C correspond with respectiveprocess segments “A, C, D, E” of the process shown in FIG. 1A.

[0050] Referring to FIG. 1C, at the segment of the method illustrated at“A”, web substrate 12 is fed into the process by web unwind 70. Websubstrate 12 is slit by e.g. a web slitter 75 and separated to form twoseparate and distinct webs 12A, 12B. Webs 12A and 12B are routed alongseparate distinct manufacturing pathways wherein adhesive isintermittently applied to web 12B using adhesive applicator 71 therebyto create alternating longitudinally-spaced coated web segments anduncoated web segments. In some embodiments, the two webs e.g. 12A, 12Bhave separate and distinct origins on the manufacturing line.

[0051] Webs 12A and 12B come together in face-to-face relationship asthe respective separate manufacturing pathways of webs 12A, 12B approachone another to enable webs 12A, 12B to once again follow a common pathof manufacture. As webs 12A, 12B approach one another, elastic elements18 are fed between webs 12A, 12B, in stretched to stop condition, at anip 74 formed by first pressure roll 72 and second pressure roll 73,such that elastic elements 18 are substantially aligned with machinedirection 78. The force exerted in the nip created by first and secondpressure rolls 72, 73 urges webs 12A, 12B together and, due to theadhesive applied to web 12B, effects an adherent joinder of webs 12A,12B encompassing elastic elements 18 therein thus forming an stretchableextensible web 10 as shown at segment “A” of FIG. 1A having alternatingbonded and unbonded longitudinally-extending web segments. Webs 12A,12B, and the intervening elastic strands are bonded to each other at thebonded web segments, and are not bonded to each other at the unbondedweb segments. The bonded web segments generally correspond to theadhesively-coated web segments, and the unbonded web segments generallycorrespond to the adhesively-uncoated web segments.

[0052] While webs 12A, 12B are shown as being affixed to one anotherusing adhesive. Other methods of joining two or more webs to each otherwith elastic elements therebetween, including ultrasonic bonding andthermal bonding, will be obvious to those of ordinary skill in the art.

[0053] The inclusion of stretched elastic elements 18 in the fabricationof web 10 results in retraction of the web as the elastic elementscontract to a relaxed state when released from the manufacturingprocess, wherein the elastic elements reflect a lack of stress inmachine direction 78 of the resulting fabricated web. Methods of theinvention can be achieved, albeit with somewhat less efficiency, whenweb 10 proceeds through subsequent segments of the process havingelastic elements 18 in extensible web 10 partially stretched orcontracted to a substantially relaxed state. Thus, throughout the webfabricating methods and thus the manufacturing process of the invention,elastic elements 18 of extensible web 10 are preferably stretched tostop to enable precision in implementation of method effects, whereinthe respective distance between respective adjacent method activities,e.g. formation of non-securement zone at segment “B” of FIG. 1A, remainssubstantially constant, from web portion to web portion.

[0054] As used herein, “stretching to stop” refers to stretching aworkpiece or other element to the full extent consistent with integrityof the workpiece or element being stretched, without damage to theworkpiece or element, and without substantial irreversible stretching ofresiliently stretchable such workpiece or element.

[0055] While, for clarity, FIG. 1A shows elastic elements 18 only atportions of the manufacturing process illustrated in FIG. 1A, it shouldbe understood that such elastic strands are typically spaced along thefull widths, and extend along the full lengths, of web 10, and thatcorrespondingly, such properties generally carry through to all ofprocess segments “A-F” indicated in FIG. 1A.

[0056] In some embodiments, a substantially uniform distribution ofadhesive coating exists throughout the effective entirety of the webbetween webs 12A, 12B. In such embodiments, the activity or inactivityof the elastics does not necessarily depend upon whether adhesive hasbeen applied to the respective area of the web, but whether the elasticshave been inactivated via a severing process as discussed above.

[0057] Segment “B” of the process illustrates that elastic elements 18are preferably severed at the uncoated segments of the web, namely thoseweb segments lacking adhesive. Elastic elements 18 disposed on and/or inextensible web 10 can thus be deactivated by such severing such usinge.g. a rotary die cutter, by melt-breaking such elastic using e.g. aheated or ultrasonic function roll, or by any other means known to thoseskilled in the art for deactivating elastics. Typically, suchdeactivation breaks the respective elastic strand at an uncoated segmentof the web whereby the elastic strand retracts to the edge of theadjacent coated segment of the web. Such severing thus deactivates theelastic tension at those adjoining portions of the respective elasticelements which are not secured to the respective e.g. web 10 bysufficient securement means e.g. adhesive to counteract such retractiveforces. Thus, upon severance, the elastic elements, to the extentstretched, and not adhered to the web, retract into a generallyunstressed condition adjacent the adjoining coated/bonded web segment,thereby forming respective non-securement zones 22. The area over whichthe elastic elements so retract, non-securement zones 22, suggested bythe light sporadic lines at segment “B”, are thenceforth inactive as faras resilient stretching imparted by the elastic elements. Conversely,securement areas 20 define the areas over which elastic elements 18maintain resilient stretching characteristics relative to non-securementzones 22, the conservation of resilience of such securement areas beingdue to adherently pairing respective loci of elastic elements 18 torespective loci of webs 12A, 12B (FIG. 1C) using e.g. adhesive, suchelastics of such securement zones 20 being illustrated by the aligneduniform lines at segment “B”. Securement zones 20 generally correspondto the coated segments of the web 12B. Correspondingly, non-securementzones 22 generally correspond to uncoated segments of web 12B.

[0058] In other embodiments, web 10 does not include defined strands ofelastic elements, per se, but comprises web material which demonstrateresiliently stretchable properties such as stretch-bonded laminatematerial, neck-bonded laminate material, and/or composite elastomericmaterial. In yet other functional, yet less preferable embodiments, web10 can comprise little or no elastic wherein such web exhibits minimal,if any, elastomeric properties.

[0059] Regarding any of the aforementioned embodiments, some sub-sets ofsuch embodiments having elastic strands, elements, or properties do notinclude deactivating elastic properties in any portion of web 10. Insuch embodiments, web 10 is preferably stretched to stop throughout themanufacturing process to enable precision in placement and/or affixationof subsequent web elements.

[0060] At segment “C” of the manufacturing process illustrated in FIG.1A and FIG. 1C, reinforcement patches 23 are disposed ontonon-securement zones 22 of extensible web 10. Such reinforcement patchesare affixed to the non-securement zone using a known means of affixingfirst and second web elements to one another, preferably adhesive and/orultrasonic bonding.

[0061] Reinforcement patch 23 can comprise a variety of woven andnonwoven fabrics. For example, reinforcement patch 23 can be a non-wovenweb of polymeric material selected from the group consisting ofpolyolefins including polyethylenes and polypropylenes, polyesters, andpolyamides, and mixtures, copolymers, and blends of such polymericfibers. Reinforcement patch 23 can also comprise a carded and/or bondedweb composed of natural and/or synthetic fibers. Reinforcement patch 23typically comprises a fibrous web defining a multiplicity of small e.g.microporous openings randomly spaced between the fibers and according tolocation and orientation of the fibers, extending from a major surfaceof the web into the interior of the web. Such small openings typicallyextend through the entirety of the thickness of the web.

[0062] Reinforcement patch 23 can be fabricated using structuralcomponents selected from the group consisting of porous foams,reticulated foams, apertured polymeric films, polymeric fibers, andnatural fibers, and such patch can comprise a multiplicity of componentsor layers which correspond to any of the materials disclosed herein, aswell as others known in the art.

[0063] At segment “D” of the manufacturing process illustrated in FIGS.1A, 1C, fastener material 24 is bonded to at least a portion ofreinforcement patch 23 of extensible web 10 using ultrasonic energyapplied by e.g. ultrasonic bonding apparatus. As an alternative toultrasonic energy, such bonding can be implemented using e.g. thermalenergy, adhesives, or a combination of adhesives with ultrasonic energyor thermal energy.

[0064] Some embodiments comprise fastener material which effectivelyspans substantially the entire width “W1” of extensible web 10 whereinthe width of the web defines the distance between most remote portionsof web 10 perpendicular to machine direction 78. In such embodiments,fastener material 24 is preferably, but not necessarily, cut and trimmedin a subsequent step(s) of the process.

[0065] Referring back to segment “C” of the process, reinforcement patch23 is preferably affixed to non-securement zone 22 to provide structuralintegrity to web 10. However, some embodiments do not include theapplication of a reinforcement patch to the web. In such embodiments,fastener material is bonded directly to web 10 using one or more ofultrasonic energy, thermal energy, adhesives, or any other means ofaffixing a fastener material to a web known to those of ordinary skillin the art.

[0066] Fastener material 24 defines an attachment structure(s) which,e.g. in combination with the fastener receptive area, can be repeatedlyfastened, released, adjusted and re-fastened. Acceptable embodiments offastener material can include any material capable of formingcooperative engagement relationships with the respective material usedfor the fastener receptive area(s). For example and without limitation,such acceptable fastener materials are adhesives, cohesives, tapes,mechanical fasteners such as buttons and corresponding buttonholes,snaps and the like, as well as other fasteners which can be repeatedlyfastened and released known to those skilled in the art. Mechanical hookand loop fasteners are preferred because of their associated versatilityand cost effectiveness.

[0067] Segment “E” of the manufacturing process of FIGS. 1A, 1C showsoptional die-cuts 25A, 25B, 25C being effected preferably entirelythrough fastener material 24, through reinforcement patch 23, andthrough underlying web 10 using e.g. die/cut-out apparatus 77 topreferably shape the area of the web comprising fastener material 24,thereby e.g. improving conduciveness of such areas, upon furtherprocessing into fasteners 98, 99, to wearer manipulation of a resultantpersonal care absorbent article 80 of FIG. 4.

[0068] Some embodiments have fastener material, and optionallyreinforcement patches, that does not require subsequent trimming. Insuch embodiments, segment “E” is omitted from the process.

[0069] At segment “F” of the manufacturing process illustrated in FIG.1A, individual resilient web elements or web articles are preferablysevered from extensible web 10 thus to define individual separate anddiscrete webs 30 suitable for use in making personal care absorbentarticles. Such severing can be effected by a cutting of the assembledweb in a cross-machine direction at desired spaced web locations usinge.g. a knife and anvil cut-off. Such cut is made in the cross-machinedirection through respective reinforcement patches 23 and fastenermaterial 24 bonded to such reinforcement patches, as well as throughwebs 12A, 12B, and any elastic elements 18 which may not have fullyretracted when cut at process segment “B”.

[0070] Rather than severing or separating individual separate anddiscrete resilient webs 30 at fastener material 24 as illustrated, therespective cuts can be effected, instead, at an in-line productionstation in a subsequent stage of an absorbent article manufacturingprocess wherein web 10 is processed and incorporated into absorbentarticles.

[0071] In alternative methods, the respective cuts can be effected,instead, as lines of weakness such as, e.g. perforations, an array ofcuts, or the like, with complete severance at every “n” workpieces. Suchprocess results in strips of respective separate and discrete resilientwebs 30, each strip containing “n” resilient webs 30. The strip can thenbe rolled up for processing into personal care absorbent articles, orpackaging and shipping of such rolled up strip to a manufacturer ofpersonal care absorbent articles.

[0072]FIG. 1B illustrates a resilient web 30 fabricated using methods ofthe invention illustrated in FIGS. 1A, 1C, and cut off as a single webworkpiece. Resilient web 30 comprises a first end 14 and a second end16. A first patch 26 of fastener material is disposed at first end 14 ofresilient web 30, and similarly, a second patch 28 of fastener materialis disposed at second end 16 of resilient web 30. First and secondpatches 26, 28 of fastener material are disposed on and bonded torespective portions of reinforcement patches 23 which are, in turn,affixed to one of webs 12A, 12B.

[0073] In alternative embodiments, resilient web 30 does not includeelastic elements, per se, but comprises web material which demonstrateelastomeric properties such as stretch-bonded laminate material,neck-bonded laminate material, and/or composite elastomeric materialsuch as those described in U.S. Pat. No. 4,863,779 herein incorporatedby reference in its entirety. Other embodiments can comprise elastic atleast in and/or on portions of resilient web 30. Other less preferableembodiments comprise little or no active elastic in and/or on web 30,thus resulting in a web which demonstrates substantially no elastomericproperties.

[0074] Referring to FIGS. 2A, 2B, the invention comprehends apparatusand methods for fabricating an intervening element 40 suitable forcooperative use as an attachment surface for affixing ones of resilientwebs 30 thereto. As with the processes of FIGS. 1A, 1C, respectivesegments of the respective exemplary illustrated manufacturing processof the invention are alphabetically designated in FIG. 2A, indicatingsuch segments using letters “AA-BB”.

[0075] Referring to FIG. 2A at the segment of the method illustrated at“M”, landing zone material 48 is superimposed on substrate web 11 in asurface-to-surface relationship and bonded or otherwise affixed to suchweb to form receiver web 13. In some embodiments, the landing zonematerial has a width substantially equal to the width “W2” of web 11,each width defining the cross-machine direction distance between mostremote portions of the respective material or web. In other embodiments,the landing zone material has a width less than the width of web 11.Whereas landing zone material 48 is preferably affixed to web 11 whileeach of web 11 and landing zone material 48 is in the form of acontinuous web, some embodiments include one or both of landing zonematerial 48 and web 11 being applied as segments or fragments to theother of such material or web.

[0076] As used herein “affixing” means joining webs and/or webcomponents using adhesive, heat, ultrasonic bonding, and/or other knownmeans of bringing webs together to form a combined unit. “Affixing”shall encompass intermittently or entirely effecting such bringingtogether across a surface of one or more of the desired webs and/orcomponents, point and/or partial areal applications of such unitingmeans, and any other means of joining landing zone material 48 to web 11such that resultant receiver web 13 fares as a unitary composite web.

[0077] At segment “BB” of the manufacturing process illustrated in FIG.2A, individual intervening elements 40 are preferably severed fromreceiver web 13 thus to define individual separate and distinctintervening elements 40 suitable for use in making personal careabsorbent articles. Such severing can be effected by a cutting of theassembled web in a cross-machine direction at desired spaced weblocations using e.g. a knife and anvil cut-off. Such cut is made in thecross-machine direction preferably passing through both web 11 andlanding zone material 48.

[0078] As with the methods of FIG. 1A, rather than completely severingor separating individual separate and discrete intervening elements 40from receiver web 13 as illustrated in FIG. 2A, the respective cuts canbe effected, instead, at an in-line production station in a subsequentstage of an absorbent article manufacturing process wherein receiver web13 is processed and incorporated into absorbent articles.

[0079] Alternatively, the respective cuts in the receiver web can beeffected as lines of weakness such as, e.g. perforations, an array ofcuts, or the like, with complete severance at every “n” workpieces. Suchprocess results in strips of respective separate and discreteintervening elements 40, each strip containing “n” intervening elements40. The strip can then be rolled up for processing into personal careabsorbent articles, or packaging and shipping of such rolled up strip tomanufacturers of personal care absorbent articles.

[0080]FIG. 2B illustrates an intervening element 40 fabricated usingmethods of the invention, such intervening element having a first end 42and a second end 44, and comprising at least web 11 and landing zonematerial 48.

[0081] The patch of landing zone material 48 typically encompassingsubstantially the entireties of the lengths and the widths of web 11.While the patch of landing zone material 48 is illustrated as being aone-component, generally rectangular-shaped piece of landing zonematerial, the landing zone material, comprising a fastener receptivearea, can be defined by a variety of shapes and sizes, and any desirednumber of separate components.

[0082] Landing zone material 48 can comprise material which preferablyhas e.g. loop properties or hook material properties. In thealternative, any material which can form a cooperative relationship withdesired fastener materials, such as those suggested in the discussion ofsegment “D” of the process, to provide repeatable fastening andreleasing properties is suitable for use as, or in place of, landingzone material 48 as long as such material's engagable compliment is usedas the fastener material.

[0083] In some embodiments, web 11 comprises a material which inherentlydemonstrates landing zone properties capable of forming engagementrelationships with respective fastener materials defined in step “D” ofthe process. In such embodiments, the step of the manufacturing process,which includes applying a patch of landing zone material 48 to web 11,is not included in the process since at least a portion, and up to theentirety, of the major surface of web 11 already includes fastening areaproperties.

[0084] Therefore, a landing zone may or may not have distinct physicaledges, depending on whether the fastening properties desired to beperformed thereby (i) are provided by distinct separate e.g. webelement(s) or (ii) are integral with a surface of front portion web 26.

[0085]FIG. 3 illustrates a resilient web 30 of the invention, e.g. ofFIGS. 1A, 1B, and an intervening element 40 of the invention, e.g. ofFIGS. 2A, 2B. FIG. 3 also illustrates how resilient web 30 and element40 can be engaged to form a self-supporting composite web 15 having afirst resilient web workpiece 50, a second resilient web workpiece 60,wherein each of first and second resilient web workpieces 50, 60comprises a resilient web 30, and an intervening element 40 between suchfirst and second resilient web workpieces 50, 60. Intervening element 40has a first end 42, a second end 44, and a third length 46. Similarly,first resilient web workpiece 50 has a third end 52, a fourth end 54,and a first length 56; and second resilient web workpiece 60 has a fifthend 62, a sixth end 64, and a second length 66.

[0086] In FIG. 3, fastener material 24 is affixed to a major surface atleast near each end of each respective resilient web workpiece e.g. 50,60, so as to allow such fastener material of such resilient webworkpiece to overlie and thus create a cooperative engagementrelationship with landing zone material 48 of the respective interveningelement e.g. 40, wherein a portion of the respective length e.g. 56, 66of such resilient web workpiece e.g. 50, 60 overlies a portion of thelength e.g. 46 of the respective intervening element.

[0087] Fastener material 24 as illustrated herein defines attachmentstructures which, e.g. in cooperation with landing zone material 48, orthe like, can be repeatedly fastened, released, adjusted and re-fastenedto the landing zone material. Acceptable embodiments of fastenermaterial 24 can include any material capable of forming cooperativeengagement relationships with the respective material used as or on thelanding zone area defined by landing zone material 48. For example andwithout limitation, such acceptable fastener materials are adhesives,cohesives, mechanical fasteners such as buttons and correspondingbuttonholes, snaps and the like, as well as other fastener materialswhich can be repeatedly fastened and released, known to those skilled inthe art. Mechanical hook and loop fasteners are preferred because oftheir associated durability and consumer acceptance. In someembodiments, hook material, and the like, commonly used in the art asfastener material, is employed in the landing zone area of element 40,and cooperating loop material, and the like, commonly used in the art aslanding zone material, is employed in the fastener areas of workpieces50, 60.

[0088] The landing area can be occupied and effected by material whichpreferably has e.g. loop properties or hook material properties. In thealternative, any material which can form a cooperative relationship withdesired fastener materials, such as those suggested in the discussionabove of the process, to provide repeatable fastening and releasingproperties is suitable for use as, or in place of, landing zone material48.

[0089] A continuous composite web of indefinite length, or substantiallyany desired length, can be constructed by bringing together alternatingones of resilient webs 30 and intervening elements 40, generally asillustrated in FIG. 3. As seen in FIG. 3, fastener elements 24 onrespective resilient webs 30 overlie end portions of adjoiningintervening elements 40. By applying pressure urging the fasteners andintervening elements together, the fasteners become affixed to theintervening elements thus to join the resilient web to the respectiveintervening element. Such joining can be effected at respectiveoverlying/overlapping portions of resilient webs and interveningelements at respective ends of a so-constructed length of composite web.For example, the composite web illustrated in FIG. 3 contains threecomponents, namely, first and second resilient webs 50, 60, andintervening element 40. The composite web of FIG. 3 can be extended toany desired length by adding additional components. For example, asecond intervening element (not shown) can be added at end 64 ofworkpiece 60 in a relationship reflecting that shown by the interveningelement 40 which is shown, thus to make a 4-component composite web.Similarly, a third resilient web 30 can be added on the distal end ofthe second intervening element thus to make a 5-component composite web.

[0090] Each such component is joined in the web by urging the respectivefasteners and receptor e.g. loop material toward each other at theoverlapped end areas. The joinder so formed e.g. by hook and loopfastener system, is effective to provide primary structure and strengthto the web between the respective web components. As contemplatedherein, such joinder at the fasteners provides the sole structure andstrength of the web between the respective web components. Such web isthus well represented by a repeated iteration of resilientweb—intervening element—resilient web—intervening element, in as manyrepeated iterations as desired.

[0091] Such composite web can be formed independently in an off-lineprocess and e.g. wound up in roll form for future use. In thealternative, such composite web can be formed on line, as one feedstream into a manufacturing line which is fabricating personal care,e.g. absorbent article, an assembly portion of such manufacturingprocess being illustrated in FIG. 5.

[0092] Referring to FIG. 5, the invention comprehends methods forassembling personal care absorbent articles. Respective segments of theexemplary illustrated manufacturing process of the invention areindicated by letters “AAA-EEE”.

[0093] At the segment of the method illustrated at “AAA”, a stream ofworkpieces 17, representative of composite web 15 of FIG. 3, travelsalong a manufacturing path in the machine direction indicated bydirectional arrow 78. In the embodiment illustrated in FIG. 5, stream ofworkpieces 17 is representative of the self-supporting composite web 15and rear web 19, as well as any other personal care article componentsemployed or affixed, both directly and indirectly, to such webs.

[0094] While only resilient webs 30 of self-supporting web 15 areillustrated comprising elastic elements 18 in FIG. 5, some embodimentscomprise elastic elements in and/or on at least portions, up tosubstantially the entirety, of rear web 19 as well.

[0095] At segment “BBB” of the manufacturing process, crotch element 101is attached to intervening element 40 of self-supporting web 15 at leastat or near inner edge 110 of intervening element 40, and to rear web 19at least at or near inner edge 114 of rear web 19. In the illustratedembodiment, crotch element 101 is attached to surfaces of interveningelement 40 and rear web 19 which surfaces are directed away from theviewer. Accordingly, crotch element 101 is shown in dashed outline atthe respective intervening elements 40 and webs 19. FIG. 4 shows crotchelement 101 in solid outline. The attachment of crotch portion 101 toweb 15, 19 operates as a unifying bridge joining webs 15, 19 to eachother as a web sausage 21.

[0096] Crotch element 101 generally comprises a substrate web,supporting an absorbent core 86, and leg elastic 89 (FIG. 4), althoughsuch components can be added to crotch element 101 during other portionsof the manufacturing process. Crotch element 101 is preferably attachedto intervening element 40 and rear web 19 via adhesives, although otherattachment means known to those skilled in the art are contemplated, forexample ultrasonic bonding.

[0097] At segment “CCC” of the manufacturing process, web sausage 21 isfolded at centrally-disposed crotch portion 83 of crotch element 101such that self-supporting web 15 and rear web 19 are disposed in anoverlying and facing relationship with one another wherein respectiveouter edges 112, 116 of respective webs 15, 19 preferably, but notnecessarily, are substantially overlying one another. Such folding ofweb sausage 21 can be effected using a folding mechanism such as, butnot limited to, a helical folder or a folding bar.

[0098] As used herein, “web sausage” includes single and multiple webs,or multiple web elements and components thereof, used as basis or othersubstrate upon which to build personal care absorbent articleworkpieces. Where multiple webs are used, a second such multiple web canoverlie a first such web, or, as illustrated in FIG. 5, first and secondwebs can be advanced in a side-by-side arrangement, spaced from eachother.

[0099] At segment “DDD” of the manufacturing process of FIG. 5, sideseam bonds 94 are formed adhering portions of resilient web 30 ofself-supporting composite web 15 to rear web 19 between respectiveadjacent individual workpiece precursors 96. Bonds 94 are preferablyformed using ultrasonic energy applied by e.g. ultrasonic bondingapparatus. As an alternative to ultrasonic energy, side seam bonds 94can be implemented using e.g. thermal energy, adhesives, or acombination of adhesives with ultrasonic energy or thermal energy.

[0100] At segment “EEE” of the manufacturing process, individualworkpiece precursors 96 are preferably severed from the web sausage thusto define individual separate and distinct finished personal carearticle products. Such severing can be effected by a cutting in across-machine direction along each respective side seam 94 using e.g. aknife and anvil cut-off. Such cut is made between edges 102, 104 so asto define a bonded such side seam on each of the two articles so definedat each respective cut.

[0101] In alternative methods of manufacturing personal care articlescomprising resilient webs of the invention, a segment of web 15 of FIG.3 can be severed from such web 15, the segment of web 15 comprisingintervening element 40, a portion of resilient web 50 including fourthend 54, and a portion of resilient web 60 including fifth end 62.Referring also to FIGS. 4 and 5, the segment of web 15 can subsequentlybe incorporated into a personal care article precursor/web sausage bybonding most remote areas of respective portions of resilient webs 50,60 of the segment of web 15 to respective side sections 90, 92 usingside seams bonds 94 at respective edges 102, 104 of the personal carearticle precursor/web sausage wherein resilient webs 50, 60 are bondedto the respective side sections using adhesive or ultrasonic bonding,although other affixation means known to those skilled in the art arecontemplated. Intervening element 40 is thus joined to the respectivepersonal care article precursor/web sausage of the invention by affixingsuch intervening element to crotch element 101 of such personal carearticle precursor/web sausage using e.g. adhesive as an affixationagent.

[0102]FIG. 4 illustrates a personal care absorbent article 80 of theinvention including a front portion 81 having a central section 88, afirst side section 90, and a second side section 92, a rear portion 82and crotch portion 83. Additionally, personal care absorbent article 80also comprises an absorbent core 86 mounted between bodyside liner 85and outer cover 84. Landing zone 97, typically comprised in interveningelement 40, is disposed at an outer surface e.g. of central section 88of front portion 81 and cooperates with first fasteners 98 of a firstlateral section 93, and second fasteners 99 of a second lateral section95 in creating a cooperative engagement relationship. Such engagementrelationship enables a user, in combination with elastic elements 18 oflateral sections 93, 95, to fasten, unfasten and re-fasten fasteners 98,99 on landing zone 97 thereby to adjust waist sizing of the personalcare absorbent article. During use, and optionally during packaging,each of the fasteners, e.g. second fastener 99, is releasably secured tolanding zone 97. Lateral sections 93, 95 are typically derived fromresilient webs 30 through e.g. workpieces 50, 60.

[0103] Leg elastics 89 are shown extending generally along the areasperipheral to opposing sides of absorbent core 86, following the contourof personal care absorbent article 80, through crotch portion 83 andending at or near front portion 81 and rear portion 82. Leg elastics 89function to gather the material at the side edges of crotch portion 83along leg openings 87. Leg openings 87 are formed as apertures in thepersonal care absorbent article as front portion 81 is secured to rearportion 82 via side seam bonds 94 at edges 102, 104 thus to form apersonal care article e.g. as illustrated in FIG. 4.

[0104] Various types of elastic materials are known for use in legelastics 89. Leg elastics 89 typically provide overall retractivetensions of from about 10 grams to about 400 grams on a given legopening at stretch-to-stop conditions. Preferably, leg elastics 89provide tensions of about 50 grams to about 220 grams. More preferably,leg elastics 89 provide tensions of about 80 grams to about 200 grams.

[0105] The personal care absorbent article of FIG. 4 includessignificant portions of self-supporting composite web 15 of FIG. 3.Referring to FIGS. 3, 4, landing zone 97 of central section 88 of frontportion 81 of personal care absorbent article 80 comprises anintervening element 40 manufactured using the process described withrespect to FIGS. 2A, 2B. First lateral section 93 and second lateralsection 95 each comprise a significant portion of first and secondresilient web workpieces e.g. 50, 60.

[0106] A variety of materials can be employed as components of web 11(FIG. 2A) and/or web substrate 12 (FIG. 1A), in fabricating personalcare articles of the invention. Various woven and nonwoven fabrics canbe used for bodyside liner 85, as well as any or all of web 11,substrate web 12, and web 19. For example, bodyside liner 85 and/or oneor more of web 11, substrate web 12, and web 19 can comprise one or moreof e.g. a melt-blown, spunbonded, or other non-woven web of polymericmaterial selected from the group consisting of polyolefins includingpolyethylenes and polypropylenes, polyesters, and polyamides, andmixtures, copolymers, and blends of such polymeric fibers. Bodysideliner 85 and/or any one of web 11, substrate web 12, or web 19 may alsocomprise a carded and/or bonded web composed of natural and/or syntheticfibers. The bodyside liner and/or any one of web 11, substrate web 12,or web 19 can be composed of a substantially hydrophobic materialwherein the hydrophobic material is treated with a surfactant orotherwise processed to impart a desired level of wetability andhydrophilicity.

[0107] Bodyside liner 85 and/or any one of web 11, substrate web 12, orweb 19 can comprise nonwoven, spunbonded, polypropylene fabricfabricated with 2.8-3.2 denier fibers, formed into a web having a basisweight of e.g. about 22 grams per square meter and a density of e.g.about 0.06 grams per cubic centimeter. The fabric is preferably surfacetreated with e.g. about 0.3 weight percent of a surfactant. Bodysideliner 85 and/or any one of web 11, substrate web 12, or web 19 typicallycomprises a fibrous web defining a multiplicity of small e.g.microporous openings randomly spaced between the fibers and according tolocation and orientation of the fibers, extending from a major surfaceof the web into the interior of the web. Such small openings typicallyextend through the entirety of the thickness of the web.

[0108] Addressing structure, bodyside liner 85 and/or any one of web 11,substrate web 12, or web 19 can be fabricated using material selectedfrom the group consisting of porous foams, reticulated foams, aperturedpolymeric films and laminates, polymeric fibers, and natural fibers.Bodyside liner 85 and/or any one of web 11, substrate web 12, or web 19can comprise a multiplicity of components or layers which correspond toany of the materials disclosed herein, as well as to others known in theart.

[0109] It is generally preferred that outer cover 84 of crotch portion83 and rear portion 82 of the personal care article be formed from amaterial which is substantially impermeable to liquids. A typical outercover 84 for crotch portion 83 and rear portion 82 can be manufacturedfrom a thin plastic film or other flexible liquid-impermeable material.For example, outer cover 84 can be formed from a film of polymericmaterial selected from the group consisting of polyolefins includingpolyethylenes and polypropylenes, polyesters, and polyamides, andmixtures, copolymers, and blends of such polymeric materials, havingthicknesses, for example, of from about 0.012 millimeter to about 0.13millimeter.

[0110] In embodiments where outer cover 84 of crotch portion 83 and rearportion 82 should have a more cloth-like feel, the outer cover cancomprise a polyethylene film having a nonwoven web, such as a spunbondedweb of polyolefin fibers, bonded to a surface thereof. For example, apolyethylene film having a thickness of about 0.015 millimeter can havethermally or otherwise bonded thereto a spunbonded web of polyolefinfibers having fiber thicknesses of from about 1.5 to about 2.5 denierper filament, which spunbonded web has a basis weight of e.g. about 24grams per square meter.

[0111] Further, outer cover 84 of crotch portion 83 and rear portion 82can be formed of a woven or nonwoven fibrous web which has been totallyor partially constructed or treated to impart a desired level of liquidimpermeability to selected regions which are e.g. adjacent or proximateabsorbent core 86.

[0112] Still further, outer cover 84 of crotch portion 83 and rearportion 82 can optionally be composed of a micro-porous material whichpermits vapors to escape from absorbent core 86 and through outer cover84 while preventing liquid exudates from passing through the outercover.

[0113] One or both of outer cover 84 and bodyside liner 85 can comprisea fibrous web defining a multiplicity of randomly-spaced small openingsextending from a major surface of the web into the interior of the web.Polymeric material such as the recited polyolefins includingpolyethylenes and polypropylenes, polyesters, and polyamides, andmixtures, copolymers, and blends of such polymeric materials can be usedin either film form or in non-woven fiber form, for one or both ofbodyside liner 85 and outer cover 84. As to bodyside liner 85, films areapertured films. As to outer cover 84, fibrous webs are impermeable toe.g. aqueous liquid.

[0114] Included in the definition of polymeric material above are allroutine, common, normal additives known to those skilled in the art ofpolymeric materials such as processing aids, chemical stabilizers,compatibilizers e.g. where more than one polymer is used, fillers, andthe like.

[0115] Absorbent core 86 suitably comprises hydrophilic fibers, such asa web or matt or loose collection of cellulosic fluff, in combinationwith a high-absorbency material commonly known as super-absorbentmaterial. Absorbent core 86 preferably comprises a mixture ofsuper-absorbent hydrogel-forming particles and wood pulp fluff. In placeof the wood pulp fluff, one can use synthetic, polymeric, melt-blownfibers or a combination of melt-blown fibers and natural fibers. Thesuper-absorbent material can be substantially homogeneously mixed withthe hydrophilic fibers or can be otherwise combined into absorbent core86.

[0116] Alternatively, absorbent core 86 can comprise a laminate offibrous webs and super-absorbent material or other suitable means ofmaintaining a super-absorbent material in a localized area. Absorbentcore 86 can additionally comprise an un-creped through air dried paperweb material known as UCTAD.

[0117] Absorbent core 86 can have any of a number of shapes. For exampleand without limitation, absorbent core 86 can be rectangular, I-shapedor T-shaped. In such products as e.g. diaper-like articles, pull-onpants, and the like, absorbent core 86 is preferably narrower in thecrotch portion than in the rear portion or the front portion, especiallywhere the crotch portion of the personal care article is narrower thanthe rear portion or the front portion.

[0118] The high-absorbency material in absorbent core 86 can be selectedfrom natural, synthetic and modified natural polymers and materials. Thehigh absorbency material can be inorganic material, such as silica gels,or organic compounds, such as cross-linked polymers. The high absorbencymaterial refers to any structure or composition, along with associatedprocess, which renders normally water-soluble material substantiallywater insoluble but swellable, whereby absorbent properties areavailable but the swelled material is substantially immobile afterabsorbing water-based liquid. Such super-absorbent material can befabricated by creating e.g. physical entanglement, crystalline domains,covalent bonds, ionic complexes and associations, hydrophilicassociations such as hydrogen bonding, and hydrophobic associations, orVan der Waals forces. Two such super-absorbents are DRYTECH® 2035 M andFAVOR® SXM 880. DRYTECH® available from the Dow Chemical Company,Midland, Mich. FAVOR® is available from Stockhausen, Inc., Greensboro,N.C.

[0119] Personal care articles of the invention can be used in at leasttwo different ways. First, personal care absorbent article 80 of FIG. 4,as shipped to the customer, can be used as a pant-type structure. Insuch format, first and second fasteners 98, 99, respectively, are, andremain, attached separately to landing zone 97 of front portion 81. Thepant-type structure is slipped onto the wearer while retainingattachment of first and second fasteners 98, 99 to landing zone 97 ofpersonal care absorbent article 80 through a cooperative engagementrelationship.

[0120] Accordingly, the legs of the wearer are inserted through waistopening 91, and through leg openings 87. The pull-on pant is then pulledin a cephalic direction until leg openings 87 are snugly positioned atthe groin of the wearer. The wearer can adjust the fitting of thepant-type structure to create a better relative positioning of the waistportion of the respective personal care article about the torso of thewearer, directed toward comfort of the wearer, thus to improve the fit.

[0121] Further adjusting to obtain a tighter or looser fit can beaccomplished by the user by subsequent grasping and pulling of firstand/or second fasteners 98, 99, of first and second lateral sections 93,95, respectively, away from landing zone 97, thereby to disengage firstand/or second fasteners 98, 99 from landing zone 97. Respectivefasteners 98, 99, are then moved over desired location on landing zone97, thus increasing or decreasing relative tension of elastic elements18 associated with lateral sections 93, 95, and re-engaged to landingzone 97, so as to achieve the desired relationship between adjusted sizeof personal care absorbent article 80 and size of the wearer. Releaseand refastening of fasteners 98, 99 can occur multiple times (e.g. anindeterminate number of times) to enable proper fitting throughout theexpected use life of the personal care article. Fasteners 98, 99 offirst and second lateral sections 93, 95 can be adjusted individually orin combination with each other to create a relatively tighter orrelatively looser fit.

[0122] Preferably, and as a user convenience, personal care articles ofthe invention are packaged having first and second fasteners 98, 99,cooperatively affixed in an engagement relationship with landing zone97, whereby personal care articles of the invention can be put on awearer in a similar fashion to that of conventional pull-on pants.

[0123] The second method of using personal care absorbent article 80 ofFIG. 4 is to use such article as a diaper-like article. Before puttingthe diaper-like article on the prospective wearer, first and secondfasteners 98, 99 are separated from landing zone 97 of personal careabsorbent article 80, and front portion 81 is pulled away from rearportion 82. In the method of using such article as a diaper-likearticle, the separation of first and second fasteners 98, 99 fromlanding zone 97 can be performed before packaging by the manufacturer,or can be performed anytime prior to or during use by the user. Afterfasteners 98, 99 are separated from landing zone 97, the personal carearticle is laid on a preferably horizontal surface with bodyside liner85 facing upwardly. The dorsocaudal portion of the torso of the wearer(e.g. infant or adult) is then laid or otherwise moved onto rear portion82 of the personal care article. Front portion 81 is then broughtfrontwardly between the legs of the wearer and onto the torso of thewearer. First and second fasteners 98, 99 are fastened to landing zone97, completing the application of the personal care article onto thewearer. Those skilled in the art will recognize the instant abovedescription as a known method of putting a diaper-like article on awearer.

[0124] Alternative methods of putting on a diaper-like article will beobvious to those of ordinary skill in the art. Such alternative methodsinclude, but are not limited to, e.g. putting the diaper-like article ona wearer when such wearer is in a position other than lying down, e.g.standing, and/or when such wearer's slacks/pants are not entirelyremoved, but rather, lowered to expose the lower trunk and groin regionof the wearer.

[0125] Those skilled in the art will now see that certain modificationscan be made to the apparatus and methods herein disclosed with respectto the illustrated embodiments, without departing from the spirit of theinstant invention. And while the invention has been described above withrespect to the preferred embodiments, it will be understood that theinvention is adapted to numerous rearrangements, modifications, andalterations, and all such arrangements, modifications, and alterationsare intended to be within the scope of the appended claims.

[0126] To the extent the following claims use means plus functionlanguage, it is not meant to include there, or in the instantspecification, anything not structurally equivalent to what is shown inthe embodiments disclosed in the specification.

Having thus described the invention, what is claimed is:
 1. A method offabricating a web suitable for use in making a personal care absorbentarticle, the method comprising: (a) fabricating a resiliently extensibleweb by bringing together and securing to each other (i) web substrateelements, and (ii) resiliently stretchable elastic elements in stretchedcondition, the securement between the elastic elements and the websubstrate elements being defined by alternating zones of securement andnon-securement of the elastic elements to at least one of the websubstrate elements along a length of the web substrate; (b) deactivatingelastic elements in the non-securement zones thereby (i) to attenuateresilient retraction of the web in such non-securement zones in responseto activity of the elastics and correspondingly (ii) to distinguish thesecurement zones as relatively more resiliently stretchable and thenon-securement zones as relatively less resiliently stretchable; and (c)applying, to the relatively non-stretchable non-securement zones,patches of mechanical fastener material extending generally betweenrespective adjacent ones of the relatively more resiliently stretchablesecurement zones.
 2. A method of fabricating a workpiece suitable foruse in a personal care article, comprising creating such workpiece froma web fabricated as in claim 1, including defining a first end of suchworkpiece by defining a free end of the web through a respective patchof the hook fastener material, and separating the workpiece from the webthrough a second respective patch of the hook fastener material suchthat hook fastener patch material is defined at opposing end portions ofthe respective workpiece.
 3. A method of fabricating an extensible webfrom respective ones of first and second workpieces, and wherein suchweb is suitable for use as a substrate in making a personal carearticle, the method comprising arranging workpieces defined in claim 2in generally end-to-end relationship with intervening elements, andreleasably attaching the hook material on the workpieces to hookreceptive areas on the intervening elements, thus to releasably attachthe workpieces to the intervening elements in fabricating a length ofthe extensible web.
 4. A method as in claim 3 wherein the releasableattachment of the workpieces to the intervening elements comprises theonly attachment between the workpieces and the intervening elements. 5.A method as in claim 3, the method comprising developing an alternatingarrangement of the workpieces and the intervening elements such thateach such workpiece is between two such intervening elements and eachsuch intervening element is between two such workpieces.
 6. A method offabricating a extensible web and wherein such web is suitable for use asa substrate in making a personal care article, the method comprisingarranging workpieces as in claim 2 in generally end-to-end relationshipwith intervening elements, respective ones of the intervening elementshaving lengths and widths defining respective surface areas, the hookreceptive areas of such respective intervening elements generallycorresponding to such surface areas, the method including releasablyattaching the hook material on the workpieces to the interveningelements at the hook receptive areas, thus to releasably attach theworkpieces and the intervening elements to each other in fabricating alength of the extensible web.
 7. A method as in claim 1, includingdeactivating elastic elements in the non-securement zones by cuttingsuch elastic elements.
 8. A method as in claim 1, including deactivatingelastic elements in the non-securement zones by applying ultrasonicenergy to such elastic elements through an intervening layer.
 9. Amethod of fabricating a web suitable for use in making a personal careabsorbent article, the method comprising: (a) fabricating a base webcomprising multiple workpieces; (b) applying patches of mechanicalfastener material to such base web; and (c) defining a first end of suchworkpiece by defining a free end of the base web through a respectivepatch of the fastener material, and separating the workpiece from thebase web through a second respective patch of the fastener material suchthat a patch of fastener material is defined at both opposing endportions of the respective workpiece.
 10. A method of fabricating a webfrom respective ones of first and second workpieces, and wherein suchweb is suitable for use as a substrate in making a personal carearticle, the method comprising arranging workpieces defined in claim 9in generally end-to-end relationship with intervening elements, andreleasably attaching the fastener material on the workpieces to fastenerreceptive areas on the intervening elements, thus to releasably attachthe workpieces to the intervening elements in fabricating a length ofcomposite web.
 11. A method as in claim 10 wherein the releasableattachment of the workpieces to the intervening elements comprises theonly attachment between the workpieces and the intervening elements. 12.A method as in claim 10, the method comprising developing an alternatingarrangement of the workpieces and the intervening elements such thateach such workpiece is between two such intervening elements and eachsuch intervening element is between two such workpieces.
 13. A method offabricating a web and wherein such web is suitable for use as asubstrate in making a personal care article, the method comprisingarranging workpieces as in claim 10 in generally end-to-end relationshipwith intervening elements, respective ones of the intervening elementshaving lengths and widths defining respective surface areas, thefastener receptive areas of such respective intervening elementsgenerally corresponding to such surface areas, the method includingreleasably attaching the mechanical fastener material on the workpiecesto the intervening elements at the fastener receptive areas, thus toreleasably attach the workpieces and the intervening elements to eachother in fabricating a length of the composite web.
 14. A method as inclaim 9 wherein said fastener material comprises a mechanical hookmaterial.
 15. A method as in claim 10 wherein said intervening elementscomprise a material which demonstrates fastener receptive properties,wherein the material of said intervening element is capable of formingengagement relationships with respective fastener materials.
 16. Amethod as in claim 10 including affixing said fastener receptive area,as a separate web element, to said intervening element, wherein saidfastener receptive area has distinct physical edges.
 17. A method as inclaim 10, said fastener receptive area being integral with a majorsurface of said intervening element, said fastener receptive area, thus,being void of distinct physical edges.
 18. A method as in claim 9, saidbase web comprising a neck-bonded laminate or a stretch-bonded laminate.19. A method of fabricating a self-supporting web of material fromrespective workpieces and intervening elements, wherein suchself-supporting web is suitable for use in making a personal carearticle, the method comprising: (a) bringing together an interveningelement having first and second ends, a first workpiece having third andfourth ends, and a second workpiece having fifth and sixth ends, withfirst, second, and third lengths of the respective first and secondworkpieces and the intervening element aligned with each other in agenerally common surface, and with the second and third lengths of thefirst and second workpieces operating as extensions of the first lengthof the intervening element, on opposing ones of the first and secondends of the intervening element; and (b) releasably attaching (i) thefirst workpiece and the intervening element to each other at therespective first and fourth ends, using releasable fasteners, and (ii)releasably attaching the second workpiece and the intervening element toeach other at the respective second and fifth ends, using releasablefasteners, such that the first, second, and third lengths, incombination, define a self-supporting web segment having a fourth lengthand wherein the fourth length of the web segment so defined by thecombination of the first, second, and third lengths is greater than anyof the first, second, and third lengths, individually, of the respectivefirst and second workpieces and the intervening element, and whereinadditional such alternating workpieces and intervening elements can bereleasably attached to one or both of the third and sixth ends of therespective first and second workpieces using additional releasablefasteners, to thereby further extend the length of the self-supportingweb, and wherein the releasable fasteners employed in so assembling theself-supporting web can be released so as to release respective ones ofthe workpieces and intervening elements of the self-supporting web fromeach other.
 20. A method as in claim 19 wherein the second and thirdlengths of the first and second workpieces are defined at rest, whereinthe first and second workpieces are resiliently extensible by at least100 percent of the respective second and third lengths, the methodincluding attaching the first and second workpieces to the interveningelement while the respective first and second workpieces are stretchedsubstantially to stop.
 21. A method as in claim 19 wherein the secondand third lengths of the first and second workpieces are defined atrest, wherein the first and second workpieces are resiliently extensibleby at least 100 percent of the respective second and third lengths, themethod including attaching the first and second workpieces to theintervening element while the respective first and second workpieces arebeing subjected to a stretching tension stretching the lengths of therespective first and second workpieces at least 50 percent from therespective second and third lengths.
 22. A method as in claim 19 whereinthe second and third lengths of the first and second workpieces aredefined at rest, wherein the first and second workpieces demonstrateeffectively no elasticity, the method including attaching the first andsecond workpieces to the intervening element.
 23. A method as in claim19 wherein the first and second workpieces are attached to theintervening element by fasteners having attachment capability over asubstantial portion of an area defining the intervening element.
 24. Amethod as in claim 19 wherein the first and second workpieces areattached to the intervening element by first and second attachmentsdefining mechanical hook fasteners on one of the respective workpiecesand/or the intervening element interacting with mechanical loops on theother of the respective workpieces and/or the intervening element.
 25. Amethod as in claim 19, including fabricating a web of indefinite lengthby adding alternating workpieces and intervening elements to the websegment so as to develop a self-supporting web of indefinite lengthwherein support of such self-supporting web along the indefinite lengthof such web is defined by the alternating workpieces and interveningelements making up the web.
 26. A method as in claim 19, includingdefining, in the workpieces, hook-type mechanical fasteners effective toengage the intervening elements.
 27. A method as in claim 19 wherein thereleasable attachment of the workpieces to the intervening elementscomprises the only attachment between the workpieces and the interveningelements.
 28. A self-supporting web of sheet material suitable for usein making a personal care article, said self-supporting web comprising asequence of at least first and second workpieces and interveningelements, including opposing ends on the respective workpieces andintervening elements, the respective workpieces and intervening elementshaving unstressed lengths between the respective ends thereof, theunstressed lengths of the respective workpieces and intervening elementsbeing aligned with each other in a generally common surface, andoperating as extensions of each other, such that the unstressed lengths,in combination, define a length of said web, said workpieces andintervening elements, in combination, defining self-supportinglongitudinal strength of said web, the workpieces and interveningelements being releasably attached to each other, using releasablefasteners, and wherein the releasable fasteners employed in soassembling the web can be released so as to release respective ones ofthe workpieces and intervening elements from the self-supporting web.29. A self-supporting web as in claim 28 wherein ones of the workpiecescan be resiliently extended at least 100 percent from the unstressedlengths of the respective workpieces.
 30. A self-supporting web as inclaim 28, including employing hook and loop fastening structure ineffecting the releasable fastening of the workpieces and interveningelements.
 31. A self-supporting web as in claim 28 wherein thereleasable attachment of the workpieces to the intervening elementscomprises the only attachment between the workpieces and the interveningelements.
 32. A method of fabricating personal care absorbent articles,comprising: (a) advancing along a processing line a first web having afirst length, the first web being suitable for use in making a personalcare article, and comprising at least workpieces and interveningelements releasably attached to each other using releasable fasteners tothereby define such first web and self-supporting longitudinal strengthof such web, whereby such workpieces and intervening elements generallydefine the structure and the structural integrity of the first web; (b)concurrently advancing a second web having a second length along theprocessing line and generally parallel to the first web, and defining aspace between the first and second webs, the second web being suitablefor use in making such personal care article; (c) applying and attachingabsorbent crotch portion elements to the first and second webs at spacedintervals along the lengths of the respective webs, and bridging thespace between the first and second webs, thereby to form a composite webcomprising the first and second webs and the respective crotch portions,a given respective crotch portion element having a front segmentattached to the first web and a rear segment attached to the second web;(d) bringing the first and second webs of the composite web into facingrelationship with each other, including bringing the respective frontand rear segments of the respective crotch portion elements into facingrelationship with each other; (e) forming side seam bonds joining thefirst and second webs to each other at spaced locations along the lengthof the composite web, thereby to form a composite web sausage having anindefinite length; and (f) separating discrete lengths of the compositeweb sausage from the indefinite-length composite web sausage at orproximate respective ones of the side seam bonds, thereby to definerespective personal care articles.
 33. A method as in claim 32 whereinsuch workpieces can be resiliently extended at least 100 percent fromunstressed lengths thereof.
 34. A method as in claim 32, includingreleasably attaching the workpieces to the intervening elements byemploying mechanical fasteners and corresponding hook receptive areas onrespective ones of the workpieces and intervening elements.
 35. A methodas in claim 32 wherein the releasable attachment of the workpieces tothe intervening elements comprises the only attachment between theworkpieces and the intervening elements.
 36. A personal care articlecomprising a front portion, a rear portion, and a crotch portionextending between said front portion and said rear portion, said frontand rear portions each comprising opposing first and second sidesections and a central section between the respective side sections,said rear portion and said front portion being attached to each other atrespective side sections of the front and rear portions by side seams,said front portion comprising first and second workpieces correspondingto the side sections of the front portion, and an intervening elementcorresponding to the front central section, the first and secondworkpieces being releasably attached to the intervening element byreleasable fasteners, the releasable fasteners, prior to use by a user,comprising the only attachment attaching the first and second workpiecesto the front central section.
 37. A personal care article as in claim 36wherein said first and second workpieces can be resiliently extended atleast 100 percent from unstressed lengths thereof.
 38. A personal carearticle as in claim 36 wherein said releasable fasteners comprisemechanical fasteners, received in hook receptive material defined atsaid intervening element.
 39. A personal care article as in claim 36wherein said first and second workpieces are attached to the interveningelement by fasteners having attachment capability over a substantialportion of an area defining the intervening element.
 40. A personal carearticle as in claim 36 wherein the first and second workpieces areattached to the intervening element by first and second attachmentsdefining mechanical fasteners on one of the respective workpieces and/orthe intervening element interacting with mechanical loops on the otherof the respective workpieces and/or the intervening element.